Box forming apparatus



May 21, 1968 LO-ROY K. CHEU E AL 3,383,990

BOX FORMING APPARATUS Filed Jan. 17, 1966 5 Sheets-Shet 1 LO-ROY K. CHEUc. VANHOUDEN KING Q INVENTORS. I

lownsend lownsend May 21, 1968 LO-ROY K. CHEU ET AL 3,383,990

BOX FORMING APPARATUS 5 Sheets-Sheet 2 Filed Jan. 17, 1966 OY K. CHEULO-R c. VAN HOUDEN KING INVENTORS.

lownsend o 'Iownsend y 1968 LO-ROY K. CHEU ET 3,383,990

BOX FORMING APPARATUS Filed Jan. 17, 1966 5Sheets-Sheet s LO-R K. CHEUc. v HOUQEN KING NVENTORS.

BY Ioumsend "wlownsend May 1968 LO-ROY K. CHEU ET 3,383,990

BOX FORMING APPARATUS 5 Sheets-Sheet 4 Filed Jan. 17, 1966 LO-ROY K.CHEU C. VAN HOUDEN KING INVENTORS.

BY 'lownsend ba'lownsend May 1968 LO-ROY K. CHEU ET AL 3,383,990

BOX FORMING APPARATUS Filed Jan. 17,. 1966 5 Sheets-Sheet 5 LO-ROY K.CHEU C. VANHOUDEN KING INVENTORS.

lownsend v Iownsend United States Patent Filed Jan. 17, 1966, Ser. No.521,207 6 Claims. (Cl. 93-49) This invention relates to a machine forfolding paperboard boxes in a fiat configuration and for completing thebottom closure of such box while retaining the remainder of the box insuch flattened condition.

A box blank of the type that the present invention is particularlysuitable for folding is described in commonly assigned copendingapplication, Ser. No. 454,423, filed May 10, 1965, now abandoned. Suchbox is formed so that the bottom closure flaps of the box can beadhesively or otherwise joined to one another, and the box folded flatwithout interfering with the integrity of such bottom closure.Consequently, the box can be conveniently shipped flat in an emptycondition and can be quickly set up for filling when such is desired.The present invention includes apparatus for automatically forming suchbox from a box blank and for delivering the box in a flattened conditionwith the bottom closure completely and permanently formed.

The apparatus exemplifying the invention that is described in detailhereinafter includes a folding section and a bottom closure formingsection. The folding section is arranged so that forward movement of thebox blank is imparted by engagement of the bottom flaps of the boxblank, thereby permitting performance of folding operations on the upperpanels of the box blank. The bottom closure forming section includesmeans for advancing the box by engagement with only the side panels ofthe folded box blank so that the bottom closure flaps can be manipulatedand glued without interference with the forward movement of the box.Consequently, the apparatus is capable of high speed operation becausethe folding and gluing operations are performed while the box is moving.

The apparatus of the present invention is completely adjustable so thatboxes of different dimensions can be handled by only minor adjustmentsof components of the device. Therefore, the apparatus is extremelyversatile.

The present invention has for another object provision of a method bywhich box blanks can be formed with bottom closures and folded fiat inan efficient and rapid sequence of steps.

Other objects, features and advantages of the present invention will bemore apparent on referring to the following specification andaccompanying drawings in which:

FIG. 1 is a perspective view of the apparatus of the present invention;

FIG. 2 is a perspective view at enlarged scale of an input station ofthe folding section of the apparatus;

FIG. 3 is a perspective view similar to FIG. 2 showing a box blank inplace in the folding section;

FIG. 4 is a perspective view of the folding and compressing section ofthe folding section;

FIG. 5 is a perspective view of the output end of the folding sectionand the input end of the bottom closure forming section showing transferof a box blank from the former to the latter;

FIG. 6 is a perspective view of the portion of the bottom closureforming section showing mechanism for manipulating the lower flaps ofthe box blank;

FIG. 6A is a detail view of a fragment of FIG. 6;

FIG. 7 is a perspective view of a central portion of the bottom closureforming section of the apparatus; and

FIG. 8 is a perspective view of the output end of the gluing station.

3,383,990 Patented May 21, 1968 Referring more particularly to thedrawing and specifically to FIG. 1, the apparatus includes a foldingsection 12 and a bottom closure forming section 14 for automaticallyfolding and gluing bottom flaps of the box blank into a completed bottomclosure. Folding section 12 has an input station 16 (see FIG. 2) whichincludes a projecting lower input bar 18 on which box blank B isinitially received from conventional conveying apparatus, not shown, orby manual placement thereon by a human operator. A frame 20 is providedfor supporting folding section 12, and input bar 18 is mounted to andspaced above the frame by an amount sufficient to permit lower sideflaps 22 of box blank B to depend in coplanar relationship with sidepanel 24 of the box blank. The input bar is adapted to bend forwardlower end flap 26 and rear lower end flap 28 upwardly and rearwardlyinto a horizontal position on the bar. Input station 16 also includesside bars 30 for affording lateral support to box blank B by engagementwith side panels 24 thereof. Side bars 30 are carried in frame members32 which afford lateral adjustment of the bars so as to accommodate boxblanks of different sizes. Supported above the side bars is a top bar 34which is carried in a frame member 36 so as to afford verticaladjustment of the top bar. As shown more clearly in FIG. 2, top bar 34is positioned to bend upper forward flap 36 and upper rear flap 38 ofbox B into a rearwardly extending horizontal position.

Spaced along the path of travel of the box blank and at the samehorizontal level and coplanar with bar 18 is a plate 49 defining smoothupper and lower surfaces and here shown as being formed by two laterallyspaced-apart plate segments 40a and 40b for weight reduction. Beneathplate 40 are lower side flap plow members 41 which converge in thedirection of forward movement so that lower side flaps 22 of box B arefolded upwardly into contact with the lower surface of plate 40. Themotive power for moving box B into the position shown in FIG. 3 isprovided either manually or from automatic feeding apparatus not shown.

,Spaced along the path of travel from input station 16 is an endlessbelt 42 having an upper reach 42a parallel to and in close proximitybeneath plate 40. Conveyor 42 is so driven (by conventional means notshown) that upper reach 42a moves forwardly. Therefore, the lowersurface of side flaps 22 is frictionally engaged by conveyor reach 42aand box B is thereby moved forwardly with the upper portion thereof inan unrestricted or unimpeded condition to enable subsequent foldingoperations to be performed on the upper portion of the box. During suchforward movement the box is stabilized by support thereof on plate 40.

Spaced along the path of box travel (see FIG. 4) is a side panel foldingstation 50 which is supported above the path of box travel by a rearframe structure 52 and a forward frame structure 54. Iournalled in theframe are shafts 56 and 58 which are disposed on axes parallel with thedirection of box travel and laterally of and above the center of thepath of box travel. Shafts 56 and 58 carry at their forward ends cranks60 and 62, respectively for rotatively driving the shafts. An arm 64extends between cranks 69 and 62 so that on pivotal driving movement ofthe latter crank, the former will experience an equal amount of pivotalor rotative movement. A conventional pneumatic actuator 66 is mounted onframe 54 and has a rod 68 operatively connected to crank 62. Pneumaticcylinder 66 is controllably supplied with air from any conventionalsource, not shown. A side panel folding arm 72 is mounted on each shaft56, 58 which arm moves in response to pivotal movement of the respectiveshaft from a horizontal position above the path of travel of the boxinto a depending vertical position. Shafts 56, 58 are spaced from oneanother by an amount greater than the width of the box so that when arms72 are in a vertical position the side panels and top side flaps of thebox are bent or folded outwardly, as more clearly shown in FIG. 4. Apair of levers, one of which is exemplified at 74 in FIG. 4, supports acrossbar 76 within the path of box travel and is contacted by a passingbox. The upper end of lever 74 is operatively associated with amicroswitch 78, or like electrical control element, which actuates,through conventional electromechanical control apparatus 80 thepneumatic actuator 66 so that when the box encounters the crossbar, arms72 pivot from the horizontal position to the vertical position and foldthe side panels of the box outwardly. Such lateral folding movement ofthe sides of the box cause the leading panel of the box to sloperearwardly as more clearly shown in the figure.

Along the path of travel from the location of arms 72 is a roller 82 forsupporiing one end of an endess belt 84, the other end of which issupported on a roller 86.

Roller 82 is carried in a pair of blocks, one being shown at 88, whichare supported on a vertically adjustable mounting structure 90. Roller82 is established at a height such that lower reach 84a of conveyor belt84 converges forwardly and downwardly toward plate 48, as a consequenceof which front panel 91 and top forward end flap 37 of the box arecompressed and folding of the box is completed on passage of the boxbeneath conveyor 84.

From FIG. 4 it will be observed that box blank B is conveyed forwardlyin the folding station 58 (rightwardly in the drawing) by frictionalengagement between conveyor belt 42 and lower side flaps 22 of the boxblank. Plate segments a and 40b constrain the box blank in the path oftravel so that the upper portions of the box blank contact rod 76 andinitiate the downward pivotal movement of panel-folding arms 72. Thelateral folding or bending of side panels 24 causes front panel 91 to befolded to a rearwardly-sloping position prior to transport of the boxblank to conveyor 84. When the box blank has completed traverse ofconveyor 84 it is in a flattened condition because output roller 86 ofthe conveyor is spaced closely adjacent to plate segments 411a and 40b.

As the folded box exits from the folding section 12, the side panels andupper side flaps, in a substantially flat tened condition, projectlaterally from the remainder of the box blank including the bottomflaps. Spaced on opposite sides of the path of box travel for engagingsuch laterally extended portions of the box are upper endless belts 92and lower endless belts 94. See FIG. 5.

The forward moving reaches of belts 92 and 94 are spaced sufiicientlyclose to one another to compress and frictionally engage thelaterally-extending portions of the box blank so that forward movementof the box blank is continued. Along the path of travel from the inletside of bottom closure forming section 14, plate segments 40a and 40bare formed to unfold bottom side flaps 22 into a generally verticalposition. To accomplish such unfolding each segment is twisted 90 in agradual and continuous fashion. Such unfolding operation occurs withoutaffecting the forward movement of the box blank because such forwardmovement is imparted solely by engagement of the folded "and laterallyextending side panel between belts 92 and 94, and without restriction tomovement of the lower flaps.

Forward lower flap 26 and rear lower flap 28 are both in a trailing orrearwardly extending position; as the first step in completing thebottom closure it is necessary to fold rear flap 28 forwardly. For thispurpose a flap folding station 100 is provided along the path of boxtravel. See FIG. 6. A frame 102 for pivotally supporting a shaft 104over the path of travel is provided. Mounted on shaft 104 is a lever 166to the outer end of which is secured the rod of a pneumatic or hydraulicactuator 188. The cylinder of the actuator is secured to frame 102 by abracket 110 so that actuator 108 pivotally drives shaft 184. Beneath thepath of box travel is mounted a microswitch 112 for sensing the arrivalof the box blank beneath shaft 104. A conventional electromechanicaltransducer 114 is provided for linking microswitch 112 to actuator 108to the end that closure of the microswitch by laterally extending flaps24 will cause actuator 103 to pivotally drive shaft 104.

Secured to shaft 184 for pivotal movement therewith is a flap foldingarm 116 which includes arcua'te fingers 118 and a crossbar 120 spanningthe outer ends of the fingers.

Referring now to FIGURE 6A, arm 116 normally resides in a generallyhorizontal position spaced above the path of travel of the flattenedbox. In response to arrival of the box as sensed by microswitch 112, arm116 is driven downwardly (counter-clockwise as viewed in the figure) tofold lower flap 28 through a 180 arc and into a position underlying thebox blank. Side flaps 22 do not interfere with such action because theyare retained in a vertical position by plate segments 40a and 40b.Spaced along the path of travel from the flap-folding station is a lowerskid 112, which retains the rear flap 28 into the forwardly extendingposition established by arm 116. The rear extremity of skid 122 isformed with an upwardly, forwardly sloping portion 124 to assure asmooth transition of the box blank from folding station 102 to thegluing station of the apparatus.

Spaced along the path of box travel from rear fiapfolding section 100 isa bottom flap-gluing station 130, which includes a pair of conventionaladhesive-spreading rollers 132 mounted on opposite sides of skid 122below the path of travel. Liquid adhesive under pressure is controllablysupplied to rollers 132 by a conventional mechanism not shown. Suchmechanism typically includes an electrically-controlled valve forpermitting and arresting adhesive or glue How to the rollers.

As box blank B approaches gluing station the lower front and rear endflaps 26 and 28 retained by skid 122 in a position underlying box blankB and lower side flaps 22 are retained in a generally vertical positionby plate segments 40a and 40b. Forward movement of the box blank iscaused by engagement of the laterally-extending side flaps betweenconveyor belts 92 and 94. A first glue control microswitch 134 ismounted in the path of the laterally-extending side flaps and isoperatively connected to glue rollers 132 so that closure of themicroswitch on arrival of the boxblank causes the glue rollers to beginapplying glue to the bottom surface of front lower flap 26. Microswitch134 is mounted in a slot 136 so that the microswitch can be positionedto initiate glue application at the correct location on flap 26. Spacedalong the path of travel is a second glue control microswitch 138,actuation of which interrupts glue delivery by rollers 132. Microswitch138 is positioned so that glue delivery is interrupted at or before thepassage of the trailing edge of flap 26. A third glue controlmicroswitch 140 is provided along the path of travel and is adapted tostart glue delivery from rollers 132 when the leading edge of flap 28 isin contact with the rollers. A fourth glue control microswitch 142 isspaced along the path of travel from microswitch 140 and is adapted tointerrupt glue delivery at or before the trailing edge of flap 28.Because the microswitches are mounted in slot 136, the apparatus isadjustable to permit formation of boxes of various sizes. Thus, it willbe seen that after the box blank passes through gluing station 130,front and rear lower flaps 26 and 28 will have glue lines thereon forsecuring the lower side flaps 22 thereto for completing the bottomclosure of the box.

A lower side flap folding station 144 is spaced along the path of travelfrom the gluing station. In the inlet end of folding station 144 andbelow the path of box travel is a pair of vertically-mounted rollers146, and at the outlet end of the folding station is a pair ofhorizontally extending rollers 148. Endless belts are carried betweenrollers 146 and 148 so that side flaps 22 of the box blank are folded upinto contact with end flaps 26 and 28 during traverse of folding station144. Consequently as the box blank exits from folding station 144 thebottom closure consisting of end flaps 26 and 28 and side flaps 22 iscompleted.

The box blank is delivered to a compression section fragmentarily shownin FIG. 1 at 152 which acts to compress the box blank in a foldedcondition until the glue or like adhesive has cured or set. Thedetermination of the length of compression section 152 depends on thetime required for the adhesive to cure and is well within the knowledgeof one skilled in the art.

The completed and flattened boxes are then transported, stored andshipped in accordance with conventional practices and are readilyavailable for setting up at the place of use. Because compression beltfirmly retains the bottom closure flaps in contact during the curingperiod of the adhesive, the bottom closure is permanently formed andwill not be destroyed or weakened during shipment or subsequentunfolding for use.

Thus, it will be seen that the present invention provides apparatus forfolding a box blank into a flattened condition and for permanentlyforming the bottom closure of such box. Because both the folding and thegluing operations are performed while the box is moving, extremely highspeed of operation is obtained. Moreover, because of the particulararrangement of the components of the apparatus, it is adjustable toaccommodate boxes and/or box blanks of widely varying sizes.

Although one embodiment of the invention has been shown and described,it will be obvious that other adaptations and modifications can be madewithout departing from the true spirit and scope of the invention.

What is claimed is:

1. Apparatus for folding a box blank into a flattened condition and forforming the bottom closure of the box blank comprising a first conveyorfor engaging the lower flaps of the box blank and propelling the boxblank along a path of travel, means adjacent the path of box travelalong said first conveyor for folding the side flaps of the boxlaterally outwardly of the path of travel, a second conveyor in boxblank receiving relationship to said first conveyor, said secondconveyor engaging only the laterally extending side fiaps of the boxblank, and means adjacent the path of travel of the box blank on saidsecond conveyor for folding and gluing the bottom flaps of said boxblank to form a bottom closure panel therefor.

2. Apparatus for forming into a box, a box blank that has four sidepanels each of which includes an upper fold line for defining a topclosure flap and a lower fold line for defining a lower closure flap,said folding apparatus comprising an input station for receiving saidbox blank with the panels in a generally rectangular configuration withthe lower forward and rear flaps folded rearwardly, first and secondarms pivotally mounted adjacent said receiving station, and laterallythereof means for pivotally driving said arms downwardly and outwardlyinto contact with the interior surface of the side panels of said boxblank, a converging endless conveyor for flattening the forward panel ofsaid box against the rear panel thereof, and means at the outlet end ofsaid converging conveyor for adhesively joining the bottom flaps of saidbox blank to form a bottom closure therefor.

3. Apparatus for forming into a box a box blank that has four sidepanels each of which includes an upper fold line for defining a topclosure flap and a lower fold line for defining a lower closure flap,said folding apparatus comprising an input station for receiving saidbox blank with the panels in a generally rectangular configuration andthe lower forward and rear flaps folded rearwardly; means disposed inbox receiving relation to said input station to define a planar surfacefor supporting said lower forward and rear flaps siidably thereover;plow means mounted below said planar surface for folding the side lowerflaps upwardly into substantial contact with the lower face of saidplanar surface; conveying means for contacting the lower surface of thefolded side flaps and propelling said box blank forwardly so thatportions of the box blank above the lower flaps are moved forwardly inunobstructed condition along a path; means in the path for folding theside panels of the box outwardly, said side panel folding meansincluding first and second arms mounted for pivotal movement withrespect to axes spaced on opposite sides of the path, means forpivotally driving said arms from a generally horizontal position abovethe path to a downwardly depending position in engagement interiorly ofthe side panels, and means responsive to arrival of a box blank at saidside panel folding means for actuating said arm driving means wherebythe front and rear panels of said box blank will be folded into anupwardly converging position; means spaced along the path from said sidepanel folding means for compressing the convergent front and rear panelsinto .a substantially flattened condition; means at the output of saidcompressing means for engaging the laterally extending side panels andfor conveying the flattened box blank forwardly; and means beneath thepath of travel of last said means for adhesively joining the bottomflaps to form a bottom closure for said box.

4. Apparatus for forming a box from a box blank having upper and lowerfront flaps, upper and lower rear flaps, and upper and lower side flapsfoldably joined to a body composed for four side panels, said apparatuscomprising an input station having a center bar for folding said lowerfront and rear flaps in trailing horizontal relation, endless conveyormeans having a top reach movable away from said input station, saidinput station including guide means for folding said lower side flapsupwardly beneath said top conveyor reach, means for retaining said lowerside flaps in frictional contact with said top conveyor reach so thatsaid box is moved forwardly by said conveyor, a folding station spacedfrom said input station along said conveyor for folding the side panelsof said box blank outwardly, said folding station including a pair ofarms mounted for pivotal movement about axes aligned longitudinal ofsaid conveyor and on opposite sides thereof, means for moving said armsto a generally horizontal position above a box in said conveyor to agenerally vertical position within the box and in engagernent with theside panels thereof, means for sensing arrival of a box at said foldingstation and for activating said arm moving means toward the verticalposition, a second endless conveyor spaced along the path of box travelfrom the folding station said conveyor having a forward moving reachdisposed in overlying opposed relation to said first conveyor andconverging in the direction of movement of said conveyor, so that a boxis conveyed and compressed thereby, said guide means having divergingportions spaced from said second belt along the path of travel of saidfirst conveyor for unfolding the side bottom flaps into generallyvertically depending relation, means spaced along the path of travelfrom said diverging portions for folding the rear lower flap for-'wardly and upwardly of said box into approximately horizontalrelationship, means for applying glue to the bottom surface of saidforward and rear lower flaps, guide means having a converging portionspaced from said glue applying means along the path of travel of saidbox for folding said lower side flaps upwardly into contact with glue onthe forward and rear lower flaps, and means for compressing said box fora time sufficient for the glue to set.

5. A box forming and folding machine comprising a first endless conveyorhaving an upper reach for transporting a box along a path; an inputstructure for said conveyor, said input structure including alongitudinally extending bar ahead of said conveyor and generallycoplanar with said upper conveyor reach to afford a support for thelower front and rear flaps of the box, transversely spaced side supportsfor affording lateral support to a box intermediate said bar and saidconveyor, means defining a relatively smooth bearing surface overlyingsaid upper reach in confronting relation thereto and spaced therefrom byan amount sufficient to urge a box flap therebetween into contact withsaid upper conveyor reach, means intermediate said longitudinallyextending bar and said conveyor for folding the lower side flaps againstsaid bearing surface so that the lower side flaps are disposed betweensaid bearing surface and said conveyor for transport thereby; a foldingstructure spaced from said input structure along the path, said foldingstructure including a frame mounted above the path, first and secondarms pivotally mounted on said frame along axes generally parallel tothe path, said arms being pivotally movable between an upper positionabove a box in the path to a lower position at which the arms contactthe inner surface of the top side flaps of said box to bendably deformthe flaps outwardly, the front panel and upper front fiap being foldedrearwardly in response to outward folding of the upper side flaps, asecond end less conveyor having a lower reach said above said firstconveyor in confronting relation thereto, said second conveyorconverging toward said first conveyor along the path and having an inputend in box receiving relation to said pivotally mounted arms so that abox between said first and second conveyors is folded fiat on transportbetween said conveyors; a lower flap gluing station spaced from saidfolding structure along the path, said gluing station including upperand lower endless conveyors at the output of said first and secondconveyors, said upper and lower conveyors each including laterallyspaced belts for engaging only the laterally extending side flaps of thebox, a lower side flap guide mounted between said laterally spaced beltsfor folding the side flaps downwardly in generally vertical dependingrelation, a frame overlying said laterally spaced belts, a rear flappusher mounted on said frame for pivotal movement about an axisgenerally transverse of the path, means responsive to the arrival of abox beneath said pusher for pivotally actuating said pusher to move thelower rear flap of said box forwardly and beneath the box into ahorizontal position, means for applying glue to the lower surfaces ofsaid front and rear lower flaps, means for folding the side lower flapsinto contact with the lower glued surface of said front and rear flaps;and conveyor means for compressing said box for a duration sufficient topermit the glue to set.

6. A method for forming and folding a box comprising the steps oftransporting the box along a path, folding the front and rear lowerflaps in trailing relation to the box, folding the lower side flaps intosubstantially coplanar relationship With the trailing flaps, pulling thelateral panels outwardly and downwardly of the box, compressing theoutwardly folded panels to flatten the box, unfolding the bottom sidepanels, folding the rear bottom flap forwardly, applying adhesive to thebottom surface of the front and rear flaps, folding the side flaps intocontacting relation with the adhesive on the front and rear flaps, andretaining the box in a compressed condition for a duration suflicient tocure the adhesive.

References Cited UNITED STATES PATENTS BERNARD STICKNEY, PrimaryExaminer.

1. APPARATUS FOR FOLDING A BOX BLANK INTO A FLATTENED CONDITION AND FORFORMING THE BOTTOM CLOSURE OF THE BOX BLANK COMPRISING A FIRST CONVEYORFOR ENGAGING THE LOWER FLAPS OF THE BOX BLANK AND PROPELLING THE BOXBLANK ALONG A PATH OF TRAVEL, MEANS ADJACENT THE PATH OF BOX TRAVELALONG SAID FIRST CONVEYOR FOR FOLDING THE SIDE FLAPS OF THE BOXLATERALLY OUTWARDLY OF THE PATH OF TRAVEL, A SECOND CONVEYOR IN BOXBLANK RECEIVING RELATIONSHIP TO SAID FIRST CONVEYOR, SAID SECONDCONVEYOR ENGAGING ONLY THE LATERALLY EXTENDING SIDE FLAPS OF THE BOXBLANK, AND MEANS ADJACENT THE PATH OF TRAVEL OF THE BOX BLANK ON SAIDSECOND CONVEYOR FOR FOLDING AND GLUING THE BOTTOM FLAPS OF SAID BOXBLANK TO FORM A BOTTOM CLOSURE PANEL THEREFOR.